Replicating method for surface finish inspection

Abstract

A method of inspecting the surface finish of a component comprising providing an original surface to be inspected. A release agent is applied onto the original surface and an epoxy mixture is applied over the release agent. The epoxy mixture is allowed to harden into a replicated surface. Once the epoxy mixture has hardened, the replicated surface is removed and a metallic coating is applied thereon. The coated replicated surface is then ready for inspection.

What is claimed is:  
     
       1. A method of inspecting a hard-to-access surface finish of a component comprising: 
       providing an original surface on the hard-to-access surface;  
       applying release agent onto the original surface;  
       applying an epoxy over the release agent;  
       allowing the epoxy to harden into a replicated surface;  
       removing the replicated surface;  
       applying a metallic coating onto the replicated surface; and  
       inspecting the coated replicated surface.  
     
     
       2. The method of  claim 1  wherein the epoxy is a mixture comprising charcoal. 
     
     
       3. The method of  claim 2  wherein the epoxy is a mixture comprising 5% or less charcoal by volume. 
     
     
       4. The method of  claim 1  wherein applying a metallic coating comprises sputtering a metallic coating of gold or aluminum or silver. 
     
     
       5. The method of  claim 1  wherein the metallic coating applied is 20 to 40 angstroms thick. 
     
     
       6. The method of  claim 1  wherein the coated replicated surface is inspected using a scanning electron microscope. 
     
     
       7. The method of  claim 1  wherein the coated replicated surface is inspected using an optical microscope. 
     
     
       8. The method of  claim 1  wherein the coated replicated surface is inspected using an interferometer. 
     
     
       9. The method of  claim 1  wherein the release agent is a petroleum distillate.